BUILDING A KX500AF with a 2007 KX250F chassis
- Sandblaster
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Re: BUILDING A KX500AF with a 2007 KX250F chassis
Thanks to Motorrad I was further examining the fitment between the cylinder and the engine cases.
Looks like some improvement is required...
Then I checked out this cylinder that was removed from a bottom end on Friday.
Notice the gasket material hanging into the ports?
BAD!
Before my gasket goes on it will be matched.
Looks like some improvement is required...
Then I checked out this cylinder that was removed from a bottom end on Friday.
Notice the gasket material hanging into the ports?
BAD!
Before my gasket goes on it will be matched.
If bikes are for kids I'll never grow up.
Re: BUILDING A KX500AF with a 2007 KX250F chassis
Rick Peterson dyno testing a base gasket that hang into the transfer .250" and it didn't change the dyno numbers. Just like a mismatch at exhaust outlet and header flange.
- Sandblaster
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- Joined: Thu Jun 07, 2012 3:50 pm
- Location: Eugene, OR
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Re: BUILDING A KX500AF with a 2007 KX250F chassis
Interesting.
I wouldn't do it on my build.
What do you do on yours?
I really like this article:
http://www.hallbergs.net/kx500/
I have seen it referenced many times in the past few years but I finally sat down and read it.
Here's some pics of their port work.
I wouldn't do it on my build.
What do you do on yours?
I really like this article:
http://www.hallbergs.net/kx500/
I have seen it referenced many times in the past few years but I finally sat down and read it.
Here's some pics of their port work.
If bikes are for kids I'll never grow up.
Re: BUILDING A KX500AF with a 2007 KX250F chassis
It doesn't hurt to trim them up. On my devcon motor I have to make a base gasket.
- Sandblaster
- Posts: 6313
- Joined: Thu Jun 07, 2012 3:50 pm
- Location: Eugene, OR
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Re: BUILDING A KX500AF with a 2007 KX250F chassis
Made a trip to the welders last week and got all the mounts welded up.
You can remove and install the engine if you remove the gas tank.
You can remove and install the engine if you remove the gas tank.
If bikes are for kids I'll never grow up.
- Sandblaster
- Posts: 6313
- Joined: Thu Jun 07, 2012 3:50 pm
- Location: Eugene, OR
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Re: BUILDING A KX500AF with a 2007 KX250F chassis
I finally spent some time on this project today.
I made another version of the two piece clutch cover to keep the cost as low as possible.
I think 5 profiles and all the holes can be machined in one set up, then the last step would have to be done one at a time unless a jig was made.
But for now, no jig..
I'm getting quotes on the material and the machining.
I hope to have some news fairly soon.
After a few of us verify the design viability then I will let every one know the cost.
Then, I will look at making custom covers and a slightly different design
I made another version of the two piece clutch cover to keep the cost as low as possible.
I think 5 profiles and all the holes can be machined in one set up, then the last step would have to be done one at a time unless a jig was made.
But for now, no jig..
I'm getting quotes on the material and the machining.
I hope to have some news fairly soon.
After a few of us verify the design viability then I will let every one know the cost.
Then, I will look at making custom covers and a slightly different design
If bikes are for kids I'll never grow up.
- Sandblaster
- Posts: 6313
- Joined: Thu Jun 07, 2012 3:50 pm
- Location: Eugene, OR
- Contact:
Re: BUILDING A KX500AF with a 2007 KX250F chassis
Here is the next challenge..
The gas tank hits the head even without the petcock valve.
As shown earlier, I destroyed my last tank so I will be a bit more careful when molding this one
Using a Petcock valve and remote reservoir from a KLX450 will help the problem but it is not a cure all...
Since I burned a hole in mine using a heat gun last time I am going try boiling my next one.
The gas tank hits the head even without the petcock valve.
As shown earlier, I destroyed my last tank so I will be a bit more careful when molding this one
Using a Petcock valve and remote reservoir from a KLX450 will help the problem but it is not a cure all...
Since I burned a hole in mine using a heat gun last time I am going try boiling my next one.
If bikes are for kids I'll never grow up.
Re: BUILDING A KX500AF with a 2007 KX250F chassis
What pipe did you use for this bike i talk to service honda they dont know whats the best pipe for that built i saw that you use a fmf pipe what year and what model is it from?
- Sandblaster
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- Joined: Thu Jun 07, 2012 3:50 pm
- Location: Eugene, OR
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Re: BUILDING A KX500AF with a 2007 KX250F chassis
I used the Service Kawasaki pipe.
It took a little phone work and convincing to get them to sell it to me.
They said the reason for them not wanting to sell it is because these are a custom fit.
So, you may need to make some new brackets and wiggle it around.
In truth, mine fit really nice and I had to make custom brackets anyway.
If they will not sell you one then you can get the use the head section from a KX500 pipe and weld it to the rear section of the CR500 pipe which is what Service Kawasaki does
It took a little phone work and convincing to get them to sell it to me.
They said the reason for them not wanting to sell it is because these are a custom fit.
So, you may need to make some new brackets and wiggle it around.
In truth, mine fit really nice and I had to make custom brackets anyway.
If they will not sell you one then you can get the use the head section from a KX500 pipe and weld it to the rear section of the CR500 pipe which is what Service Kawasaki does
If bikes are for kids I'll never grow up.
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Re: BUILDING A KX500AF with a 2007 KX250F chassis
Is there some way I can get this diagram to print out and use to trace it on the metal to cut it with a plasma cutter and it be the n the correct size? This is for the front engin mount using the head bolts.Sandblaster wrote:I had considered a slightly different design but decided in favor of the design above:
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